~:H:OlV:D.A. ~ CB1000C CYLINDER/PISTON Date of Issue: Sept., 1982 HONDA MOTOR CO., LTD.

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Oliver Bridges
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2 r:::ij\:h:olv:d.a. 7. CYLINDER/PISTON SERVICE INFORMATION TROUBLESHOOTING CYLINDER REMOVAL PISTON REMOVAL PISTON INSTAllATION CYLINDER INSTAllATION SERVICE INFORMATION GENERAL The engine must be removed to perform cylinder/piston maintenance and inspection. 0. SPECI FICATIONS groove Piston TOP ring-to SERVICE mm (0.004 LIMIT 67.1 SECOND clearance mm mm ( ( (0.04 ( ( (0.002 (0.018 (2.641 ( ( (0.671 ( ( ( ( STANDARD Ring end gap mm ( (0.004 mm mm ( ( TOOLS Special Piston Base (2 required) Piston Ring Compressor (2 required) TROUBLESHOOTING Compression low 1. Worn cylinder or piston rings. Excessive smoke 1. Worn cylinder or piston. 2. Improper installation of piston rings. 3. Scored or scratched piston or cylinder wall. Overheating 1. Excessive carbon build-up on the piston or combustion chamber wall. Knocking or abnormal noise 1. Worn piston and cylinder. 2. Excessive carbon build-up

~ :H:OlVD.A. CB1000C CYLINDER REMOVAL Remove the cylinder head (Section 6). Remove the bolt at the lower front cylinder base and remove the cylinder. Remove the cam chain tensioner from the cylinder.

3 ~ :H:OlVD.A. CB1000C CYLINDER REMOVAL Remove the cylinder head (Section 6). Remove the bolt at the lower front cylinder base and remove the cylinder. Remove the cam chain tensioner from the cylinder. Remove the cylinder gasket and dowel pins. DOWEL PINS GASKET CYLINDER INSPECTION Inspect the cylinder bores for wear or damage. Measure the cylinder I.D. at three levels in X and Yaxis. STANDARD: mm ( SE RVICE LIMIT: 67.1 mm (2.641 TOP MIDDLE BOTTOM

4 ~:H:O:N"D.A. CYLINDER/PISTON ~ I nspect the top of the cylinder for warpage. Check in an X pattern as shown. SERVICE LIMIT: 0.10 mm (0.004 CAM CHAIN TENSIONER INSPECTION Inspect the slipper of the cam chain tensioner for damage or excessive wear. Inspect the tension spring for weakness. PISTON REMOVAL PISTON PIN Remove each piston pin clip with needle nose pliers being careful not to allow clips to fall into the crankcase. Press the piston pin out. ~ NOTE r Mark the pistons to indicate their cylinder positions. PISTON PIN CLIP

5 ~~O:N"D.A. PISTON/PISTON RING INSPECTION Inspect the piston ring-to-groove clearance. NOTE Mark the rings so that they can be returned to their original locations. SERVICE LIMIT: ~ TOP 0.09 mm (0.004 SECOND 0.09 mm (0.004 Inspect the pistons for damage and cracks; ring grooves for wear. Insert each piston ring into the cylinder, and measure the end gap. SERVICE LIMITS: TOP: SECOND: 01L (Side rail): 0.5 mm ( mm ( mm (0.04 STANDARD END GAPS: TOP: mm ( SECOND: mm ( L (Side rail): mm ( Measure the piston O. D. at the skirt, 10 mm (0.4 from the bottom. SERVICE LIMIT: mm (2.634 STANDARD: mm ( Calculate the cylinder-to-piston clearance. SERVICE LIMIT: 0.10 mm (

~:H:OlVD.A. CYLINDER/PISTON ~ Measure the piston pin hole I. D. STANDARD: 17.002-17.008 mm (0.6694-0.6696 SERVICE LIMIT: 17.05 mm (0.671 Measure the connecting rod small end I.D. (See Section 12 for rep'lacement procedure) STANDARD: 17.

6 ~:H:OlVD.A. CYLINDER/PISTON ~ Measure the piston pin hole I. D. STANDARD: mm ( SERVICE LIMIT: mm (0.671 Measure the connecting rod small end I.D. (See Section 12 for rep'lacement procedure) STANDARD: mm ( SERVICE LIMIT: mm (0.672 Measure the piston pin O.D. Determine the piston-to-piston pin clearance. SERVICE LIMIT: 0.04 mm (0.002 STANDARD: mm ( SERVICE LIMIT: mm (

7 ~ :H:OlVD.A. CB1000C PISTON RING INSTAllATION Install the piston rings with the markings facing up. After installation, the rings should rotate freely. Space the piston ring end gaps 120 degrees apart. Do not align the gaps in the oil rings. TOP (CHROME PLATES) SECOND Oil '~ / HONDA MOTOR CO., ltd.

~:H:OIVD.A. CYLINDER/PISTON PISTON INSTAllATION "IN" MARK FACING REAR Apply molybdenum disulfide grease to the connecting rod small ends. Install the pistons, piston pins and clips.

8 ~:H:OIVD.A. CYLINDER/PISTON PISTON INSTAllATION "IN" MARK FACING REAR Apply molybdenum disulfide grease to the connecting rod small ends. Install the pistons, piston pins and clips. Install the pistons with the "IN" mark toward the carburetor side. I nstall the piston pins and clips, ~ being careful not to drop the clips into the crankcase. NOTE r--- Install the pistons in their original positions. Stuff shop towels into the crankcase to catch dropped clips. CYLINDER INSTAllATION Install the cam chain tensioner. Install the dowel pi ns and gasket. DOWEL PINS GASKET

Install the cylinder. PISTON RING COMPRESSOR 07954-3690000 ~ :H:OlV:D.A. CB1000C NOTE Before using the special tools, position the No.2 and No.3 pistons at T. D.C. PISTON BASE 07958-3000000 Tighten the cylinder base nut securely after installation.

9 Install the cylinder. PISTON RING COMPRESSOR ~ :H:OlV:D.A. CB1000C NOTE Before using the special tools, position the No.2 and No.3 pistons at T. D.C. PISTON BASE Tighten the cylinder base nut securely after installation. Install a new cylinder head gasket. Install the dowel pins and carn chain guide. Install the cylinder head (Section 6)

9-0 CYLINDER/PISTON 9. CYLINDER/PISTON XCITING 500/250

9-0 CYLINDER/PISTON 9. CYLINDER/PISTON XCITING 500/250 9 CYLINDER/PISTON SCHEMATIC DRAWING ------------------------------------------------- 9-1 SERVICE INFORMATION------------------------------------------------ 9-2 TROUBLESHOOTING-----------------------------------------------------